Concoa 6500 Series Owner's manual

INSTALLATION AND OPERATION INSTRUCTIONS
Certified ISO 9001
ADI 1608-L
Controls Corporation of America
1501 Harpers Road Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com
Before Installing or Operating, Read and Comply with These Instructions
Regulators
April 2011
Supercedes September 2003

2
Warning: An appropriately sized pressure relief device downstream
of the regulator should be installed in your system to prevent damage
to equipment and/or injury to personnel should an internal failure of
the regulator occur.
Warning: Maximum allowable working pressure indicated on product
labeling is for the regulator only. Ratings for peripherals/accessories
may be less than the pressure indicated on the product label. Do not
exceed the pressure ratings of the attached peripherals/accessories
and the regulator's maximum allowable working pressure. Please
contact your gas supplier for more information.
Warning: for regulators with tube fittings, select the appropriate
tubing. Use seamless tubing with the proper consideration given
to wall thickness and material. Please contact your gas supplier for
more information.

3
USER RESPONSIBILITY
This equipment will perform in conformity with the description contained in
thismanualandaccompanyinglabelsand/orinsertswheninstalled,operated,
maintained, and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Improperly working equipment
should not be used. Parts that are broken, missing, worn, distorted or
contaminated, should be replaced immediately. CONCOA recommends
that a telephone or written request for service advice be made to CONCOA
Customer Service in Virginia Beach, Virginia, PHONE: [phone],
FAX: [phone], or E-MAIL: [email protected].
This equipment or any of its parts should not be altered without prior written
approval by CONCOA. The user of this equipment shall have the sole
responsibility for any malfunction that results from improper use, faulty
maintenance, damage, improper repair, or alteration by anyone other than
CONCOA or a service facility designated by CONCOA.
SAFETY
Specific procedures for the safe use of regulators are listed below. The
user can form habits that will prevent an accident due to confusion over
changing service needs. Refer to CONCOA publications ADE 872, latest
revision, Safe Practices in Welding and Cutting.
a. Never subject the regulator to inlet pressure greater than its rated inlet
pressure, as shown on regulator body.
b. Neverusetheregulatorforgasesotherthanthoseforwhichitisintended.
c. Checkthecylindervalveoutletbeforeattachingaregulatortoacylinder.
Do not use the cylinder if oil, greas, or dirt is present
Do not allow oil, grease, or other combustibles to contaminate
oxygen equipmentor areaswhere oxygenis inuse. Do notplace
a contaminated regulator into service.
Theregulator reliefvalve onlyprotectsthe regulator. Downstream
equipment may require additional pressure relief devices.
d. To minimize heat effects, avoid use of piping or tubing between cylinder
and oxygen regulator. If unavoidable, it should be as short as practicable
and equipped with a shutoff valve located just before the regulator. Keep
the shutoff valve closed when pressurizing. If regulator is connected to a
manifold,openthevalveofthecylinderclosesttotheregulatorfirst,thenopen
the remaining cylinder valves. In either case, when the flow to the shutoff
valvestops,wait60secondsandthenslowlyopentheshutoffvalve. DRAIN
OXYGEN REGULATOR OF GAS BEFORE PRESSURIZING.

4
e. Do not allow oil, oil-bearing materials, or other combustibles that
can ignite readily in the presence of oxygen, to contaminate the
inside or outside of oxygen regulators. Clean oil or grease, if any,
from external surfaces as described in step C. Do not place an
internally contaminated regulator into oxygen service.
f. Use oxygen regulator with equipment suitable for and used only
for oxygen service.
g. Never use a pipeline or station regulator on a high-pressure
compressed-gas cylinder or manifold.
h. Never discharge fuel gas from a cylinder valve near welding or
cuttingwork, sparksflame,or anyotherpossible sourceofignition.
i. Before attaching regulator, remove any dirt or foreign matter that
may be in the cylinder valve outlet by wiping with a clean, linfree
cloth. (See safety item c) Valves on other than combustible-gas
cylinders may be opened momentarily to blow outlet clean.
j. Never pressurize a regulator that has loose or damaged parts or is
in questionable condition. Never loosen a connection or attempt
to remove a part until gas pressure has been relieved. Under
pressure, gas can dangerously propel a loose part.
k. Beforetransporting cylinders thatarenotsecuredon acartdesigned
for such transport, remove regulators and recap the cylinders.
l. Keep cylinder handwheel or wrench on open cylinder valve at all
times, for prompt emergency shutoff.
m. Do not attempt to clean or change parts of oxygen gauge. Have
regulator reparied (see SERVICE section).
n. Theregulator reliefvalve, ifany, isdesigned toprotect theregulator
only, and nothing else. Be sure that equipment connected to the
regulator outlet is provided with relief devices to protect such
downstream equipment against possible overpressure.
o. Check regulator and ALL connections for leaks after installation,
periodically thereafter, and after any service in which parts or
connectionswere loosened. Brush withan approvedleakdetection
solution. Bubble indicate leak.
p. No repair should ever be undertaken by anyone not having
qualifications descibed in the SERVICE SECTION.

5
INTRODUCTION
1.1 SCOPE
Thismanual provides generalinformation for the installation, operation
and service of CONCOA Gas Pressure Regulators.
1.2 USE
The regulators are designed to control and reduce high gas pressure
from a cylinder or pipeline, in one or two stages, to the working
pressure required for the equipment using it.
According to design and requirements of individual regulators, the
following may be provided:
a. Ascrew,knob orsimilar deviceto adjust pressure manually and (as
in the vacuum regulator) by remote control; or to change factory
pre-set pressure (as in the pipeline regulator).
b. One or two stages of valves, seats, diaphragms, and auxilliary
parts..
c. Various types of inlet and outlet connections.
d. Built-in inlet filters, to prevent entry of solid foreign matter.
e. Gauges, to indicate inlet and outlet pressures.
f. A built-in relief valve to protect the regulator.
g. A flowmeter to measure gas flow.
h. Aflow adapter on fixed pressure regulator (See Table and Figure 1).
Table 1. FlowAdapters
Orifice
Size Stock Number Flow in Standard Cubic Ft/Hr (SCFH)*
Argon Helium CO2AG-75 Nitrogen
0.010
0.0135
0.016
0.018
0.020
0.021
0.025
0.028
0.0312
0.035
0.040
830 1977
830 1978
830 1979
830 1971
830 1984
830 1972
830 1973
830 1985
830 1974
830 1975
830 1976
4
6.3
8
10
11.4
15
20
22.5
30
40
50
12
20
25
31.5
36
47.5
63.2
72
95
126.5
158
3.5
6
7.5
9.5
10.5
14.
319
21
28
38
47.5
6.6
11
14
17.5
20
26
35
40
52.5
60
88
4.5
7.6
9.5
12
13.5
18
24
27
36
47.5
60
*Flows at 30 PSIG

6
INTRODUCTION
Figure2shows typicalregulatorparts and connectionstoa cylinder;connect
regulator as follows:
a. A observe precautions in SAFETY Section
b. Beforeconnecting regulatortoa cylinderorpipeline, slightly engage
adjusting screw (turn in clockwise) to drain regulator, then release
screw (counter clockwise). This will decrease chance of seat
ignition in an oxygen regulator.
c. Connectregulator inletconection to cylinder or pipelineand tighten
it firmly but not excessively, with a suitable wrench.
d. Connectand similarlytighten hose nutto regulatoroutlet andattach
downstream equipment as needed.
Note: Check Labels
Cylinder valve connection must match
regulator connection. Be sure regulator is
used only with gas shown on label.
Cylinder
Valve
Inlet Nut
Label
Inlet Gland
Inlet Gauge
(Cylinder
Pressure)
Outlet Gauge
(Working Pres-
sure)
Label
Outlet
Nipple
Hose To
Equipment Spring
Case
Adjusting
Screw
Cylinder
Figure 2. Typical Regulator and Connection to Cylinder
Figure1. Flow Adapter Markings
Gas flow in SCFH
on 30 PSIG Inlet
Pressure
Gas Service
ARG = Argon
HE = Helium
AG75 = 75% He, 25% Ar
CO2= Carbon Dioxide

7
OPERATION
3.1 PREPARING FOR OPERATION
With regulator connected to cylinder or pipeline downstream equipment
installed and valves closed, and the ajdusting screw released, prepare for
operation as follows:
a. Observe precautions in SAFETY Section.
b. Before pressurizing an oxygen regulator, make sure it has been
drained of residual gas.
c. Open the cylinder or upstream valve slowly to avoid a sudden
pressure surge that may damage internal regulator parts.
CAUTION
Gaswillflowfromoutletoffixed-pressureregulator whenvalveisopened.
Inlet gauge, if any, will show supply pressure. Stand to one side to avoid
injury in case of regulator failure.
d. Slowly turn adjusting screw clockwise until the outlet gauge
indicates the desired pressure.
e. Toreducepressure, allowgasto dischargefromregulator towards a
safearea, and turn adjusting screwcounterclockwise, until desired
pressure is indicated on the gauge. Stop gas discharge.
f. To prevent explosive gas mixtures, in hose or in downstream
equipment attached to regulator outlet, purge gas line by opening
equipment discharge valves and closing them after purging is
completed. (Adequatepurging time depends on length and size of
hose.) If more than one regulator is used, close one valve before
opening next one to avoid unsafe or unwanted mixture of gases.
CAUTION
Do not purge oxidizing or flammable gases in the presence of
flame, lit cigarettes, or other sources of ignition, or towards person.
g. Test connections with a leak detection solution (See SAFETY
Section; item O). If no bubbles appear, system is ready for use.
3.2 SHUTTING DOWN
Close cylinder valve whenever the regulator is not in use. To shut down
for extended periods (more than 30 minutes):
a. Close cylinder or upstream valve.
b. Open downstream valve to drain the line towards a safe area.
c. After gas is drained completely, release adjusting screw and close
downsstream valve.

8
SERVICE
4.1 GENERAL
Aunit which is not functioning properly should not be used until all required
repairs have been completed and the unit has been tested to ascertain that
it is in proper operating condition.
Inspection,troubleshooting, andrepair ofthis equipmentas indicatedin this
manual, may ordinarily be undertaken by a competent individual having
at least general experience in the maintenance and repair of equipment
of this nature. CAUTION
Maintenance should only be attempted by qualified or properly trained
individuals.
Defective parts should only be replaced with either a replacement part
manufactured or sold by CONCOA or an equivalent.
Exceptfor inspection,troubleshooting, andrepairs indicated in this manual,
it is recommended that all servicing be done by a service facility authorized
by CONCOA. Contact the CONCOA Customer Service Department in
VirginiaBeachor thenearest CONCOADistrict Sales Office forassistance.
If so advised, the unit should be sent to a service facility authorized by
CONCOA, adequately packaged, in the original shipping container if
possible, and shipped prepaid, with a statement of observed deficiency.
The gas service that the equipment has been subjected to must be clearly
identified. All equipment must be purged before shipment to protect the
transporter and service personnel. The purging is especially important if
the equipment has been in hazardous or corrosive gas service. Return
trip transportation charges are to be paid by Buyer. In all cases other than
where warranty is applicable, repairs will be made at current list price for
the replacement part(s) plus a reasonable labor charge.
Test regulator for leaks on a routine schedule.
4.2 TROUBLE INDICATIONS
Typical symptomsinthe accompanying tableindicateregulator malfunctions
requiring repair. Replace immediately with a clean, repaired and tested,
or new regulator.

9
TROUBLE SHOOTING
SYMPTOMS
1. Gas leakage at the regulator
outlet when the adjusting
screw is turned fully
counterclockwise.
2. With no flow through the
system (downstream valves
closed), outlet pressure
increases steadily above the
set pressure.
3. Gas leakage from spring case
or bonnet.
4. Excess drop in outlet pressure
with regulator flow open.
5. Gas leakage from any pipe
thread joint.
6. Gas leakage from relief valve.
7. Inconsistent repeat reading
8. Inlet or outlet pressure gauge
does not return to zero with
no pressure applied to the
regulator.
PROBABLE CAUSE
1. Seat leak or creep, have
regulator repaired.
2. Seat leak or creep, have
regulator repaired.
3. Diaphragm failure, have
regulator repaired.
4. Blockage in seat assembly
or inlet filter. Have regulator
repaired.
5. Loose fitting, remove
connection clean, reapply
Teflon tape and retighten.
6. Possible faulty relief valve,
replace. Possible seat leak
or creep, have repaired.
7. Seat sticking, have regulator
repaired. Possible bad
pressure gauge.
8. Gauge has suffered physical
damage, replace gauge.

10
THIS PAGE INTENTIONALLY LEFT BLANK

11
Warranty Information
This equipment is sold by CONTROLS CORPORATION OF AMERICA under
the warranties set forth in the following paragraphs. Such warranties are
extended only with respect to the purchase of this equipment directly from
CONTROLS CORPORATION OF AMERICA or its Authorized Distributors as
new merchandise and are extended to the first Buyer thereof other than for
the purpose of resale.
For a period of one (1) year from the date of original delivery (90 days in cor-
rosive service) to Buyer or to Buyer’s order, this equipment is warrantied to be
free from functional defects in materials and workmanship and to conform to
the description of this equipment contained in this manual and any accompa-
nying labels and/or inserts, provided that the same is properly operated under
conditions of normal use and that regular periodic maintenance and service is
performedor replacements made inaccordance with theinstructions provided.
The foregoing warranties shall not apply if the equipment has been repaired:
otherthan by CONTROLS CORPORATIONOFAMERICAor a designatedser-
vice facility or in accordance with written instructions provided by CONTROLS
CORPORATION OF AMERICA, or altered by anyone other than CONTROLS
CORPORATIONOFAMERICA,or if the equipmenthas been subjectto abuse,
misuse, negligence or accident.
CONTROLS CORPORATION OF AMERICA’s sole and exclusive obligation
and Buyer’s sole and exclusive remedy under the above warranties is limited
to repairing or replacing, free of charge, at CONTROLS CORPORATION OF
AMERICA’s option, the equipment or part, which is reported to its Authorized
Distributor from whom purchased, and which if so advised, is returned with a
statement of the observed deficiency, and proof of purchase of equipment or
part not later than seven (7) days after the expiration date of the applicable
warranty, to the nearest designated service facility during normal business
hours, transportation charges prepaid, and which upon examination, is found
not to comply with the above warranties. Return trip transportation charges for
the equipment or part shall be paid by Buyer.
CONTROLS CORPORATION OF AMERICA SHALL NOT BE OTHERWISE
LIABLE FORANY DAMAGES INCLUDING BUTNOT LIMITEDTO: INCIDEN-
TAL DAM
AGES, CONSEQUENTIAL DAMAGES, OR SPECIAL DAMAGES,
WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE, BREACH OF
WARRANTY OR OTHERWISE.
THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND
BEYOND THE WARRANTIES HEREINABOVE SET FORTH. CONTROLS
CORPORATION OF AMERICA MAKES NO WARRANTY OF MERCHANT-
ABILITY OR FITNESS FORAPARTICULAR PURPOSE WITH RESPECTTO
THE EQUIPMENT OR PARTS THEREOF.

Certified ISO 9001
ADI 1608-L
Controls Corporation of America
1501 Harpers Road Virginia Beach, VA 23454
To Order Call 1-800-225-0473 or 757-422-8330 • Fax [phone]
www.concoa.com